Device and method for forming multiple rows of meat patties

ABSTRACT

The present invention provides devices and methods for forming multiple rows of meat patties. An existing single row forming machine is modified by moving the fill slot relative to the existing stroke length so that the fill slot comes in contact or fluidly communicates with at least one newly added row of cavities. This is most easily achieved by modifying the existing fill plate and by adding cavities to the existing mold plate, so that the combination of modified plates operates with the existing stroke length (which is difficult to change), to produce multiple rows of consistent meat patties.

PRIORITY CLAIM

This application is a continuation application of, claims priority toand the benefit of U.S. patent application Ser. No. 10/454,068 filed onJun. 3, 2003, entitled, “DEVICE AND METHOD FOR FORMING MULTIPLE ROWS OFMEAT PATTIES”, now U.S. Pat. No. 6,932,997, which is a divisionalapplication of U.S. patent application Ser. No. 09/881,483, filed onJun. 14, 2001, entitled, 10 “MULTIPLE ROW MEAT PATTY FORMING APPARATUSAND METHOD”, now U.S. Pat. No. 6,592,359.

CROSS REFERENCE TO RELATED APPLICATION

The present invention relates to a U.S. application Ser. No. 09/593,466,filed on Jun. 14, 2000, entitled Device for Producing Ground MeatPatties of Beef and/or Pork, assigned to the assignee of thisapplication.

DESCRIPTION

The present invention relates in general to a meat patty formingapparatus, and more particularly to an apparatus and method for formingmeat patties using a mold plate.

BACKGROUND OF THE INVENTION

Typically, central meat forming manufacturing locations employ highvolume, high speed automated molding machines to form different shapesand sizes of meat patties, including hamburger, steak, fish, poultry andpork patties. The manufacturers distribute the patties to restaurants,grocery stores and other retail outlets. In the high volume machines, asupply hopper feeds raw meat into a food pump that pumps the meat, underpressure, into a mold cavity of a mold plate. The mold cavity istypically one or more holes extending completely through the plate. Themold plate is moved cyclically from a fill or form patty position to adischarge or stamp patty position and back to the fill position, etc.

One complete fill position to discharge position to fill position cycleis commonly referred to as a stroke. Manufacturers typically run themolding machines at sixty to ninety strokes per minute. This means thatthe machine stamps out one or more patties sixty to ninety times aminute. To increase production, the manufacturer can run the machine ata higher speed. To save wear and tear on the machine, however, themanufacturer desires to run the machine at a lower speed. Increasing ordecreasing the stroke rate therefore creates a tradeoff of benefits.

Another solution for increasing production is to increase the number ofpatties that the machine stamps out upon each stroke. Increasing thenumber of patties per stroke requires more cavities in the mold plate.Since many or most meat patty forming operations employ forming machineshaving a single row of cavities, existing forming machines are modifiedto have or new machines are obtained having multiple rows of cavities inthe mold plate.

Operating a multiple row forming machine presents new challenges tomanufacturers accustomed to the single row machines. One difficulty thatthe multiple row machines present involves the fill portion of the cycledescribed above. With single row machines, each patty forming cavitypassing across a fill slot receives the same amount of fill time. Withmultiple row machines, achieving equal filling time is more difficult,and may not be possible in a retrofitted machine. Since forming machinesare expensive, however, it is desirable to modify existing equipment, ifpossible, to achieve multiple row forming. Accordingly, a need existsfor an apparatus and method to efficiently operate and evenly fill thecavities of a retrofitted or new multiple row meat patty formingmachine.

SUMMARY OF THE INVENTION

The present invention generally provides an improved meat patty formingapparatus and method of operating the same. More particularly, thepresent invention provides an improved apparatus and method for formingmeat patties using a mold plate having multiple rows or groups of pattyforming cavities. An existing single row forming machine is modified bymoving the fill slot relative to the existing stroke length so that thefill slot comes in contact or fluidly communicates with a newly addedrow of cavities. This is most easily achieved by modifying the existingfill plate and by adding cavities to the existing mold plate, so thatthe combination of modified plates operates with the existing strokelength (which is difficult to change), to produce multiple rows ofconsistent meat patties.

The plates are modified so that the mold plate slidingly engages thefill plate when the fill plate is in fluid communication withpressurized meat contained in a fill passage. The mold plate defines atleast two rows or groups of cavities. At least one of the rows or groupsincludes a plurality of cavities and preferably each of the rows orgroups includes a plurality of cavities. The fill plate, which mayinclude one or more removable inserts, includes at least one slot thatis adapted to fluidly engage a plurality of cavities and preferablyincludes a single slot that is adapted to fluidly engage each cavity, asthe mold plate slides across the fill plate. The elongated slot, whichfills a plurality of cavities, provides for a steady, uniform flow ofmeat into the cavities and consequently results in consistent meatpatties. This is true for retrofitted as well as new machines.

In one embodiment, the multiple row meat patty forming apparatusincludes a mold plate that has a plurality of staggered rows of pattyforming cavities. A fill plate slidingly engages a surface of the moldplate. The fill plate defines a slot that is adapted to fluidly engageat least two cavities of the same row when the mold plate slides acrossthe fill plate. A fill passage disposed on the opposite side of the fillplate from the mold plate allows pressurized meat to flow through theslot and into the plurality of cavities. The forming apparatus of thisembodiment may be adapted to have two or more fill plate slots of thesame row individually engage any number of cavities or, preferably, tohave a single slot fluidly engage each cavity of a row in the moldplate.

When the mold plate of this embodiment has two rows, they may be spacedapart and the slot may be dimensioned, such that the slot fluidlyengages each cavity of the two rows at one time when the mold plateslides against the fill plate. That is, the rows are closely spacedapart and the slot is wide enough, such that at a single point in timeas the mold plate passes across the fill plate, a portion of each cavityof both rows fluidly communicates with the slot. The mold plate of thisembodiment may be adapted to provide one cavity having a larger openarea than another cavity. It also may be adapted so that the cavities ofone row have a larger open area than the cavities of another row.

In another embodiment, the multiple row meat patty forming apparatusincludes a mold plate that has a plurality of staggered rows of pattyforming cavities. A fill plate slidingly engages a surface of the moldplate. The fill plate in this embodiment defines a single row of slotsso that each cavity is adapted to fluidly engage a unique slot when themold plate slides across the fill plate. A fill passage disposed on theopposite side of the fill plate from the mold plate allows pressurizedmeat to flow through the slots and into the plurality of cavities. Inthis embodiment, a single row of slots fluidly engages staggered rows ofcavities at different times as the mold plate moves across the fillplate. Each cavity fluidly engages a unique slot.

In a further embodiment, the multiple row meat patty forming apparatusincludes a mold plate that has a plurality of stacked rows of pattyforming cavities. A fill plate slidingly engages a surface of the moldplate. The fill plate defines a slot that is adapted to fluidly engageat least two cavities of the same row when the mold plate slides acrossthe fill plate. A fill passage disposed on the opposite side of the fillplate from the mold plate allows pressurized meat to flow through theslot and into the plurality of cavities. This embodiment includesstacked rather than staggered groups or rows of cavities.

The forming apparatus of this embodiment may be adapted to have aplurality of fill plate slots, which individually or in some combinationfluidly engage each cavity or, preferably, to have a single slot fluidlyengaging each cavity in a row of the mold plate when the mold plateslides against the fill plate. The forming apparatus also includes abreather plate slidingly engaging the surface of the mold plate oppositeto the surface engaged by the fill plate, wherein the breather plate hasat least one orifice in fluid communication with a cavity.

The mold plate of this embodiment may also be adapted to include onecavity having a larger open area than another cavity. It may also beadapted to include the cavities of one row having a larger open areathan the cavities of another row.

One method of operating a multiple row meat patty forming apparatusincludes sliding a row of cavities defined by a mold plate into fluidcommunication with a slot defined by a fill plate, wherein the fillplate contacts pressurized meat. In the same direction, sliding a cavitynot in the row into fluid communication with the slot. Reversingdirection and sliding the cavity not in the row while in fluidcommunication with the slot. In the reversed direction sliding the rowof cavities into fluid communication with the slot. This method includessliding a plurality of or a row of cavities followed by one or morecavities in a mold plate across a slot, reversing the motion, andsliding the mold plate in the opposite direction. This method enablesone or more cavities to pass partially or completely across the slot.

This method further includes the step of holding the different cavity influid communication with the slot for a predetermined amount of timebefore changing direction. The dwell time enables one or more cavities,if only partially engaged by the fill slot, to obtain the appropriateamount of meat.

Another method of operating a multiple row meat patty forming apparatusincludes sliding a first cavity defined by a mold plate into fluidcommunication with a slot defined by a fill plate, wherein the fillplate contacts pressurized meat. In the same direction, sliding a row ofcavities defined by the mold plate into fluid communication with theslot. Reversing direction and sliding the row of cavities while in fluidcommunication with the slot. In the reversed direction, sliding thefirst cavity into fluid communication with the slot. This methodincludes sliding one or more cavities followed by a plurality or a rowof cavities in a mold plate across a slot, reversing the motion, andsliding the mold plate in the opposite direction. This method alsoenables the plurality or row of cavities to partially pass across theslot and further includes the step of holding the plurality or row ofcavities in fluid communication with the slot for a predetermined amountof time before changing direction.

A further method of operating a multiple row meat patty formingapparatus includes sliding a first row of cavities defined by a moldplate into fluid communication with a first set of slots from a row ofslots defined by a fill plate, wherein the fill plate contactspressurized meat. In the same direction, sliding a second row ofcavities into fluid communication with a second set of slots from therow. Reversing direction and sliding the second row of cavities while influid communication with the second set of slots. In the reverseddirection, sliding the first row of cavities into fluid communicationwith the first set of slots. This method includes a plurality ofcavities individually or in some combination slidingly engaging aplurality of slots. This method also enables the second plurality ofcavities to partially pass across the slots.

It is therefore an advantage of the present invention that an existingsingle row forming machine is readily modified to produce multiple rowsof meat patties.

Another advantage of the present invention is that a slot fluidlycommunicates with a plurality of rows of cavities and thereby increasesproduction.

A further advantage of the present invention is that the mold plateincludes having very closely spaced apart cavities so that meat pattiesare efficiently placed on a conveyor belt exiting the forming machine.

Yet another advantage of the present invention is that a plurality ofcavities can partially pass across the slot and thereby save stroke timeand stroke length for a retrofitted or a new forming machine.

Yet a further advantage of the present invention is that a single fillslot fills a plurality of cavities, which provides for a steadier flowof meat into the cavities and ultimately for more consistent meatpatties.

Other objects, features and advantages of the invention will be apparentfrom the following detailed disclosure, taken in conjunction with theaccompanying sheets of drawings, wherein like numerals refer to likeparts, elements, components, steps and processes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a fragmentary elevation sectional view of a molding machinehaving a single row meat forming apparatus;

FIG. 1B is a fragmentary elevation sectional view of a modified moldingmachine having one embodiment of the multiple row meat forming apparatusof the present invention;

FIG. 2 is a top plan view of one preferred mold plate of the presentinvention;

FIG. 3 is a top plan view of one preferred fill plate of the presentinvention;

FIGS. 4A through 4F illustrate one method of filling the preferredmultiple staggered rows of patty making cavities;

FIGS. 5A through 5F illustrate one method of filling alternativemultiple stacked rows of patty making cavities;

FIGS. 6A through 6F illustrate one method of filling cavities usingalternative multiple fill slots; and

FIGS. 7A through 7F illustrate another method of filling cavities usingalternative multiple fill slots.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings and in particular to FIG. 1A, a section ofa molding machine 10 illustrates a single row meat forming apparatus. Apump box 12 defines an inlet chamber 14 into which a food pump (notillustrated) pumps meat including hamburger, steak, fish, poultry, porkpatties and other fibrous foods. The pump box 12 defines an opening 16into which a valve cylinder 18 fits. The valve cylinder 18 includes anintake slot 20 that aligns with an output orifice defined by the walls22 of the inlet chamber 14. The valve cylinder 18 also includes anoutlet slot 24 that aligns with a fill passage 26 defined by the pumpbox 12. The valve cylinder 18 is enabled to rotate and close off theinlet chamber 14 from the fill passage 26.

A fill plate 28 covers the top of the pump box 12, including a portionof the fill passage 26. The fill plate includes a fill slot adapter 30,which preferably extends across the width of the conveyer of the moldingmachine 10. The fill slot adapter 30 defines an elongated aperture 32that extends substantially across the entire width of the fill slotadapter 30. A fill slot insert 34 fits inside the aperture 32 and alsoextends substantially across the width of the conveyer of the moldingmachine 10. The fill slot insert 34 defines at least one fill slot 36,which is discussed in detail below.

This configuration of the molding machine 10 allows for flexibility inmolding different types of fibrous meats. The manufacturer can maintaindifferent fill slot adapters 30 and thereby fill at different pointsrelative to the travel of the mold plate 38. A different fill slotadapter 30 also includes having a plurality of apertures 32 and thus aplurality of fill points. The manufacturer can also maintain differentfill slot inserts 34. For any fill slot adapter 30, the different fillslot inserts 34 provide different fill slot 36 arrangements, preferablycorresponding to different mold plates 38, as described in detail below.It should be appreciated that the fill slot adapter 30 and the fill slotinsert 34 are optional and that the present invention is operable bysimply forming one or more fill slots 36 in the fill plate 28. For thepurposes of describing this invention “fill plate” includes none, one orboth the fill slot adapter 30 and the fill slot insert 34, and in anycase, defines one or more fill slots 36.

The fill plate 28 slideably supports the mold plate 38, whereby the moldplate 38 is enabled to slide lengthwise along the fill plate 28 (i.e.,left and right in FIGS. 1A and 1B). As stated above, the mold plate 38is cyclically, slideably moveable from a fill position to a discharge orknockout position. The drive apparatus for sliding the mold plate 38 isnot illustrated, nor is the discharge or knockout apparatus, as theseare well known and not relevant to the scope of this invention, exceptthat the manufacturer or the machine builder must add or modify knockoutcups so that there is one for each new meat patty cavity. The mold plate38 defines rows or groups of cavities 40. The cavities 40 have anydesired meat patty shape and are shown simplistically in thisdescription as having a circular meat patty shape.

The cavities 40 preferably extend through the mold plate 38, so that astamping apparatus, located above the mold plate 38, can stamp meatpatties onto a conveyor belt located below the mold plate. A breatherplate 42 sits above and slideably engages the mold plate 38. Thebreather plate 42 includes at least one air pressure release passage 44,wherein a plurality of small breather holes 46 enable the cavities 40 ofthe mold plate 38 to fluidly communicate with the passage 44. The airpassage 44 enables air in the cavities to escape as the machine 10 pumpsthe cavities full of meat. A cover plate 48 sits above the breatherplate 42 and its associated passage 44. It should be appreciated thatwhile the molding machine 10 is illustrated with the pump box 12 belowthe forming plates, the present invention includes the pump box 12 beingabove the forming plates and thereby feeding meat down onto a fill plate28 that slidingly engages the mold plate 38 on the fill plate's lowersurface, wherein the breather plate 42 is disposed below the mold plate38, etc.

In either configuration, when the valve 18 is open, fluid communicationexists between the inlet chamber 14, intake and outlet slots 20 and 24,respectively, the fill passage 26, the fill slot adapter aperture 32 andthe slot 36 (or simply the slot 36 in the fill plate 28), one or morecavities 40, depending on the sliding position of the mold plate, andthe release passage 44/breather hole 46 combination, assuming at leastone cavity 40 is in a fill position. That is, the pump is enabled topump meat into the inlet chamber 14, out of the slot 36 and into a moldcavity 40 when the mold plate is in a fill position. If the pumppressure extrudes meat through the breather holes 46, the meat collectsin the release passage 44, whereby an operator slides the loose meatback into a meat hopper (not illustrated).

In FIG. 1A, the molding or forming machine 10 as configured isconstrained to one row of cavities 40. If a second row of cavities ismachined in the mold plate in back of (to the left of in FIG. 1A) theexisting row indicated by the illustrated cavity 40, the outlet of thestroke (which pushes the mold plate 38 to the right in FIG. 1A) is notlong enough so that the new cavities would reach a stamping device (notillustrated) set to the right of the forming machine 10. If the secondrow of cavities 40 is machined in the mold plate in front of (to theright of in FIG. 1A) the existing row, the inlet of the stroke (pushingplate 38 to the left) is not long enough so that the new cavities wouldreach the fill slot 36.

The machine configuration of FIG. 1A, which in one embodiment is astandard model F-26 machine made by Formax, Inc. of Mokena, Ill., is notoperable with a mold plate having multiple rows of meat patty formingcavities. It is very difficult to change the stroke length on thesetypes of machines. Moreover, longer stroke lengths for a given speedresult in less production. It is also very difficult to move the pattystamping device given the configuration of the forming machine 10 inrelation to an output conveyor that carries away stamped patties to afreezer.

Referring now to FIG. 1B, the existing forming machine 10 iseconomically adapted to form multiple rows of meat forming patties asillustrated in one embodiment of the present invention. By moving thefill slot 36 defined by the fill plate 28 towards the outlet end (to theright in FIG. 1B) of the molding machine 10, two rows of cavities 40 inthe mold plate 38 are able to fluidly communicate with the fill slot 36.In the Formax machine, this modification involves machining a new fillslot adapter 30, so that the fill slot insert 34, defining the fill slot36, mounts further towards the outlet end of the machine 10. The fillslot adapter 30 must be adapted so that it still fluidly communicateswith the existing fill passage 26 defined by the pump box 12.

A completely new mold plate can be made with a number of rows ofcavities 40, e.g., two rows, positioned so that the new fill slot 36fluidly communicates with both cavity rows during the stroke.Alternatively, the existing mold plate 38 can be modified by addingsecond, third, etc., rows of cavities 40 in front (to the right of) theexisting row, so that new fill slot 36 fluidly communicates with eachadded row. Further, the breather plate 42 may need to be modified sothat breather holes 46 reside above the new fill slot 36.

Since the Formax machine is a very popular and reliable machine, themodifications as disclosed will likely apply to many existing meat pattyforming operations. The present invention, however, applies to anyexisting forming machine, wherein the fill slot is moveable tocommunicate with a plurality of rows of meat patty forming cavities. Inmachines not having an adapter 30 or an insert 34, only the mold plate38 needs to be modified. Typically, the fill slot 36 is moved towardsthe outlet end of the machine, i.e., towards the middle of the strokecycle, to communicate with a new one or more rows of cavities machinedinto the mold plate 38. The present invention is not limited to two rowsof cavities 40 but is constrained by the stroke length, the size of thecavities and size limitations inherent in the stamping device.

As described below, advantages derived from the interface between thefill plate 28 and the mold plate 38 of the present invention apply toall retrofitted and new forming machines 10. It should be understood,therefore, that the present invention includes both existing and newforming machines 10.

Referring now to FIG. 2, one preferred mold plate 138 of the presentinvention is illustrated having a plurality of rows of mold cavities. A“row” for purposes of this invention means a single cavity, a pluralityof cavities, a group of cavities or a set of cavities that fluidlycommunicates with one or more fill slots 36 (FIGS. 1A and 1B), when themold plate 138 is in motion, before another single cavity, plurality ofcavities, group of cavities or set of cavities fluidly communicates withthe same slot or slots 36. A row may be adapted to have one or more ofthe cavities. A row is preferably a straight line of cavities having acenterline parallel to a front edge 148 of the plate 138. A row may,however, have certain cavities that are slightly staggered or offcenter, so that not every same sized cavity begins fluidly communicatingwith one or more fill slots 36 at the same time.

In one preferred embodiment, the mold plate 138 includes a front row 140of cavities 142 along a first centerline and a rear row 144 of cavities146 along a second centerline. The rows 140 and 144 each preferably havestraight centerlines that are substantially parallel with the front edge148 of the plate 138. The cavities 146 of the rear row 144 are staggeredin between, and preferably halfway between, the cavities 142 of thefront row 140. As illustrated below, the rows in another embodiment arestacked rather than staggered. In the preferred embodiment of FIG. 2,the cavities 142 of the front row 140 are slightly bigger than thecavities 146 of the rear row 144. It should be appreciated that a verysmall difference in diameter makes a significant difference in theamount of meat received by the cavities. To facilitate equal filling ofthe cavities, the mold plate 138 includes: (i) any cavity, including acavity of the same row, being a different size than any other cavity and(ii) any row of cavities having different sized cavities than anotherrow.

The mold plate is adaptable to have any number of rows greater than one.The two rows of the preferred plate 138 include five cavities 142 in thefront row 140 and six cavities 146 in the rear row 144. To facilitate adesired number of patties discharged at the knockout portion of thecycle, the mold plate is adaptable to provide any number of cavities ineach row. In one simple embodiment, the mold plate 138 defines a singlecavity in the front or rear row, which is staggered or stacked next totwo cavities of the rear or front row, respectively. When the mold plate138 has staggered rows, either the front row or the rear row can havethe greater number of cavities. The mold plate is further adaptable tohave a mix of staggered and stacked rows.

As stated above, the mold plate is adaptable to define any shapedcavity. In FIG. 2, the cavities 142 and 146 of the mold plate 138 areeach substantially circular. The circular or round cavities are employedto make hamburger, fish, chicken and other patties. Other shapes may beemployed for pork, etc. Different shapes may exist in a single row.Different rows are further adaptable to have different shaped cavities.

Referring now to FIG. 3, one preferred fill plate 128 of the presentinvention is illustrated as having an adjustable fill slot 136. Thepreferred fill plate includes a fill slot adapter 130, which flushmounts inside the fill plate 128, such that the top surface 132 of thefill plate is substantially flat and smooth. A fill slot insert 134flush mounts inside the fill slot adapter 130 and defines the preferredelongated fill slot 136, which enables fluid communication between thefill passage 26 (FIGS. 1A and 1B) and the cavities 142 and 146 (FIG. 2).Attachment devices 135, such as threaded holes or nuts that receivepreferably countersunk bolts or screws, fixedly and removably attach thefill slot adapter 130 to the fill plate 128 and the fill slot insert 134to the fill slot adapter 130.

Different fill slot adapters 130 enable the operator to fix the fillslot 136 in different places with respect to the front edge 137 of thefill plate 128. Different fill slot inserts 134 enable the operator toinstall one or more wider or narrower slots of varying end shapes suchas rounded ends or squared ends. The preferred fill slot 136 is a singleslot having a width that is between five and forty percent of thediameter of the cavities 142 and 146. The length of the slot ispreferably, substantially the same as the widest row of cavities of themold plate, e.g., the row 144 of the mold plate 128. As described above,the fill slot adapter 130 and the fill slot insert 134 are preferred butnot required, and the fill plate 128 alternatively is a single metallicstructure that defines the fill slot 136. In any case, the fill plate128 contains the fill slot 136, and for purposes of this invention, thefill plate 128 defines the fill slot 136.

Referring now to FIGS. 4A through 4F, one preferred apparatus and methodof filling a multiple cavity mold plate is schematically illustrated.For the purpose of illustration, the actual movement of meat is notshown. It should be understood by those skilled in the art, however,that when fluid communication exists between a cavity and a slot, i.e.,when the cavities pass over or under the slot, the pump extrudespressurized meat from the fill passage 26 (FIGS. 1A and 1B), through theslot, and into the cavity.

FIG. 4A includes the preferred mold plate 138 and the preferred fillplate 128 as described above. The mold plate 138 includes the front edge148, the front row 140 of cavities 142 and the staggered rear row 144 ofcavities 146. The fill plate 128 includes the front edge 137 and definesthe elongated slot 136, which preferably extends from outer edge toouter edge of the outside cavities 146 of the larger rear row 144. Thefill plate 128, in this example, slidingly engages the mold plate 138beneath the mold plate 138, so that the slot 136 is hidden and appearsin phantom. When the slot 136 fluidly engages the cavities, e.g., slidesunderneath, signaling the flow of meat into the cavities, the slotappears in solid line type. The mold plate 138 moves in the directionindicated by the arrow with respect to the stationary fill plate 128. InFIG. 4A, at a first point in time, the cavities of the rows 140 and 144of the moving mold plate 138 are returning from the patty dischargeportion of the cycle, are empty and have yet to reach the fill slot 136of the fill plate 128.

Referring to FIG. 4B, at a second point in time, the rear row 144 ofcavities 146 of the moving mold plate 138 has reached the slot 136,fluid communication exists between the slot 136 and the cavities 146 andmeat flows from the pressurized fill passage 26 (FIGS. 1A and 1B) intothe cavities 146. The cavities 142 of the front row 140 are not yet influid communication with the slot 136.

Referring now to FIG. 4C, at a third point in time, both the rear row144 of cavities 146 and the front row 140 of cavities 142 have reachedthe slot 136, whereby for an instant, fluid communication exists betweenthe slot 136 and each of the cavities of the mold plate 138. In thisinstant, meat flows from the pressurized fill passage 26 into each ofthe cavities. The preferred apparatus includes the rows 140 and 144 ofthe mold plate 138 being closely positioned and the slot 136 being wideenough, such that this situation occurs. It has been found that closelyspacing staggered rows of cavities enables more meat patties to fit ontoa given section of a conveyor belt than closely spacing stacked rows ofmeat patties. Alternatively, the cavity positioning and the slot widthcombination does not enable fluid communication to exist between theslot 136 and each of the cavities.

Referring to FIG. 4D, at a fourth point in time, the mold plate 138 hasmoved such that the back row 144 of cavities 146 has slid completelypast or has cleared the slot 136. The cavities 146 are thus notreceiving meat and may or may not be completely full of meat. The moldplate 138 has moved to its maximum point of travel in the fill portionof the cycle and has come to rest (no arrow illustrated), so that thecenter of the slot 136 is partially through and fluidly engaging thefront row 140 of cavities 142. A forming machine retrofitted formultiple row cavity filling may limit the maximum point of travelthrough the front row 140 of cavities 142. It has been found thatconsistent front row meat patties may be formed when the fill slot 136reaches midway through the back one third of the front row 140 (i.e.,approximately 16.7%). It should be appreciated however that consistencymay be improved when the slot travels substantially through orcompletely clears or passes by each of the cavities 142 of the front row140. The present invention includes each of these implementations.

The present invention includes decelerating the mold plate to a stopvirtually instantaneously, at a predetermined rate or at a plurality ofpredetermined deceleration rates. In many existing machines, mechanicallinkages driven by a motor rotating a shaft in a single rotationaldirection cause the mold plate 138 to stroke back and forth. In anycase, a dwell time, wherein the mold plate has zero velocity, andwherein the slot 136 is positioned under the front row 140 exists sothat pressurized meat has a brief amount of additional time to fill thecavities 142 of the front row 140.

Referring to FIG. 4E, the mold plate 138 reverses direction (arrowpointing towards front edge 137 of the filling plate 128) andaccelerates either at a predetermined rate or virtually instantaneouslyas previously described. The maximum velocity in the reverse directionmay be less than, equal to or greater than the maximum velocity in theinitial direction. At this fifth point in time, the slot 136 hastraversed back across, and has fluidly communicated with, the same areaof the front row 140 as in the other direction and now fluidlycommunicates again with the cavities 146 of the rear row 144. Thecavities 142 of the front row 140 now preferably have complete meatpatties ready to be stamped. The slot 136 now enables the pump tocompletely fill the cavities 146 of the rear row 144 if it did not do soon the initial pass. Referring to FIG. 4F, at a sixth point in time,both rows 140 and 144 have cleared the fill slot 136 and now move, viathe mold plate 138, with complete meat patties, towards the well knownpatty discharge or knockout apparatus.

Referring now to FIGS. 5A through 5F an alternative mold plate 238 andthe fill plate 128 illustrate a method of filling rows 240 and 244 ofcavities. The mold plate 238 includes the front edge 248, the front row240 of cavities 242 and the stacked rear row 244 of cavities 246. Thepreferred fill plate 128 includes the elongated slot 136 as describedabove. The fill plate 128 again slidingly engages the mold plate 238 andthe slot 136 is illustrated in phantom where appropriate. The mold plate238 moves in the direction indicated by the arrow with respect to thestationary fill plate 128. In FIG. 5A, at a first point in time, thecavities of the rows 244 and 240 of the moving mold plate 238 arereturning from the patty discharge portion of the cycle, are empty andhave yet to reach the slot 136 of the fill plate 128.

Referring to FIG. 5B, at a second point in time, the rear row 244 ofcavities 246, which now has stacked cavities behind the front row 240,has reached and achieved fluid communication with the slot 136.Referring to FIG. 5C, at a third point in time, the slot, if narrowenough, can pass between the rows 240 and 244 for an instant withoutfluidly communicating with either row since an appropriate amount ofmetal thickness must exist between the cavities to keep the mold plate238 from deforming during its manufacture or upon an accidental impact.The preferred staggered mold plate 138 is able to have more closelyspaced rows, which translates into more meat patties on a given sectionof a conveyor belt that transfers the stamped patties to a freezer.

Referring to FIG. 5D, at a fourth point in time, the mold plate 238 hasmoved and stopped (no arrow), so that the slot center is partiallythrough and fluidly engaging the front row 240 of cavities 242.Alternatively, the slot passes completely by or clears each of thecavities 242 of the front row 240. This alternative embodiment alsoincludes decelerating the mold plate to a stop, virtuallyinstantaneously, at a predetermined rate or at a plurality ofpredetermined deceleration rates, as described above. Further, themethod for this alternative apparatus includes providing a predetermineddwell time, wherein the mold plate has zero velocity, and wherein theslot 136 is positioned under and is enabling meat to flow to the frontrow 240 of cavities 242.

Referring to FIG. 5E, the mold plate 238 reverses direction (arrowpointing towards front edge 137 of the filling plate 128) andaccelerates either at a predetermined rate or virtually instantaneously.The maximum velocity in the reverse direction may again be less than,equal to or greater than the maximum velocity in the initial direction.At this fifth point in time, the slot 136 has traversed back across thefront row 240 and fluidly communicates again with the cavities 246 ofthe rear row 244. Referring to FIG. 5F, at a sixth point in time, bothrows 240 and 244 preferably have complete meat patties, have cleared thefill slot 136 and now move towards the patty discharge or knockoutapparatus.

The embodiments of FIGS. 4A through 4F and 5A through 5F illustrate asingle, elongated fill slot 136, which is preferred. The uninterruptedslot 136 enables a more steady and consistent flow of meat to reach thecavities. The steadier flow of meat results in good patty consistencyand uniform weight. As illustrated below, however, the single slot maybe divided into a row of slots or holes as desired by the manufacturer.

Referring now to FIGS. 6A through 6F the alternative mold plate 238 andan alternative fill plate 228 illustrate a method of filling rows therows 240 and 244 of cavities. The mold plate 238 includes the stackedrows as described above, although this alternative embodiment isadaptable to use staggered rows. The alternative fill plate 228 includesa plurality of elongated slots 236 a, 236 b and 236 c, which eachfluidly communicate with a plurality of cavities. The fill plate 228again slidingly engages the mold plate 238, and the slots 236 a, 236 band 236 c are illustrated in phantom where appropriate. The mold plate238 moves in the direction indicated by the arrow with respect to thestationary fill plate 228. In FIG. 6A, at a first point in time, thecavities of the rows 244 and 240 of the moving mold plate 238 arereturning from the patty discharge portion of the cycle, are empty andhave yet to reach the slots 236 a through 236 c of the fill plate 228.

Referring to FIG. 6B, at a second point in time, the rear row 244 ofcavities 246 has reached and achieved fluid communication with the slots236 a through 236 c. Preferably, as illustrated, each slot 236 a, 236 band 236 c extends through the entire diameter of each cavity with whichthe slot fluidly communicates, however, the slots are adaptable tocommunicate with less than the entire diameter. In this alternativeembodiment, each slot communicates with at least one cavity from eachrow and communicates with at least two cavities in one of the rows. Thatis, in another configuration, the outer slots 236 a and 236 c would onlycommunicate with a single outer cavity, respectively, of the front row140 of the staggered mold plate 138. The slots are adaptable tocommunicate with a different number of cavities, e.g., one slotcommunicates with two cavities while another slot of the same rowcommunicates with three.

Referring to FIG. 6C, at a third point in time, the slots, if narrowenough, can pass in between the rows 240 and 244 for an instant withoutfluidly communicating with either row. Referring to FIG. 6D, at a fourthpoint in time, the mold plate 238 has moved and stopped (no arrow), sothat the centers of the slots 236 a, 236 b and 236 c are again partiallythrough and fluidly engaging the front row 240 of cavities 242.Alternatively, the slots pass completely by or clear one or more of thecavities 242 of the front row 240. This alternative embodiment alsoincludes decelerating the mold plate to a stop, virtuallyinstantaneously, at a predetermined rate or at a plurality ofpredetermined deceleration rates. Further, the method for thisalternative apparatus includes a dwell time, wherein the mold plate 238has zero velocity, and wherein the slots 236 a, 236 b and 236 c arepositioned under and are enabling meat to flow to the front row 240.

Referring to FIG. 6E, the mold plate reverses direction (arrow pointingtowards front edge 237 of the alternative filling plate 228) andaccelerates either at a predetermined rate or virtually instantaneously.The maximum velocity in the reverse direction may again be adapted to beless than, equal to or greater than the maximum velocity in the initialdirection. At this fifth point in time, the slots 236 a, 236 b and 236 chave traversed back across the front row 240 and again fluidlycommunicate with the cavities 246 of the row 244. Referring now to FIG.6F, at a sixth point in time, both rows 240 and 244 have cleared thefill slots 236 a, 236 b and 236 c, have complete meat patties and movetowards the patty discharge or knockout apparatus.

Referring now to FIGS. 7A through 7F the preferred mold plate 138 andanother alternative fill plate 328 illustrate a method of filling therows 140 and 144 of cavities. The mold plate 138 includes the preferredstaggered rows. The alternative fill plate 328 includes a plurality ofelongated holes or slots 336 a through 336 k, preferably one for eachstaggered cavity, so that each hole or slot fluidly communicates with asingle cavity. The fill plate 328 again slidingly engages the mold plate138, and the slots 336 a through 336 k are illustrated in phantom whereappropriate. The mold plate 138 moves in the direction indicated by thearrow with respect to the stationary fill plate 328. In FIG. 7A, at afirst point in time, the cavities of the rows 144 and 140 of the movingmold plate 138 are returning from the patty discharge portion of thecycle, are empty and have yet to reach the slots 336 a through 336 k ofthe fill plate 328.

Referring to FIG. 7B, at a second point in time, the rear row 144 ofcavities 146 has reached and achieved fluid communication with six ofthe eleven slots or holes. Preferably, as illustrated, each slot or hole336 a through 336 k has approximately the same size and covers the samepercentage of the open area of its associated cavity. However, differentslots or holes are adaptable to cover more or less of the open areas oftheir respective cavities as desired. For instance, the slots or holescommunicating with the front row 140 can be bigger than thosecommunicating with the rear cavities. Or, the outer slots or holes canbe slightly bigger than the inner slots or holes. In this alternativeembodiment, each slot communicates with one cavity from one row and nocavities from another row. Each slot or hole is preferably unique to asingle cavity. The slots 336 a through 336 k are adaptable to have anyoblong, square or triangular shape. The slots or holes may be adapted tohave any percentage of the open area of the cavities.

Referring to FIG. 7C, at a third point in time, the slots 336 a through336 k pass in between the rows 140 and 144 and may or may not fluidlycommunicate with their respective cavities depending on the row spacingand slot or hole sizes. Referring to FIG. 7D, at a fourth point in time,the mold plate 138 has moved and stopped (no arrow), so that the centersof five of the eleven slots 336 a through 336 k are partially throughand fluidly engaging the front row 140 of cavities 142. Alternatively,the slots pass completely by or clear one or more of the cavities 142 ofthe front row 140. This alternative embodiment also includesdecelerating the mold plate to a stop, virtually instantaneously, at apredetermined rate or at a plurality of predetermined decelerationrates. Further, the method for this alternative apparatus includesproviding a predetermined dwell time, wherein the mold plate has zerovelocity, and while certain slots or holes fluidly communicate with thecavities 142 of the row 140.

Referring to FIG. 7E, the mold plate reverses direction (arrow pointingtowards front edge 337 of the alternative filling plate 328) andaccelerates either at a predetermined rate or virtually instantaneously.This alternative embodiment includes the maximum velocity in the reversedirection being less than, equal to or greater than the maximum velocityin the initial direction. At this fifth point in time, the slots 336 athrough 336 k have traversed back across the front row 140 and six ofthe eleven holes or slots again fluidly communicate with the cavities146 of the rear row 144. Referring to FIG. 7F, at a sixth point in time,both rows 140 and 144 have cleared the fill slots 336 a through 336 k,have complete meat patties and now move towards the patty discharge orknockout apparatus.

While the present invention is described in connection with what ispresently considered to be the most practical and preferred embodiments,it should be appreciated that the invention is not limited to thedisclosed embodiments, and is intended to cover various modificationsand equivalent arrangements included within the spirit and scope of theclaims. Modifications and variations in the present invention may bemade without departing from the novel aspects of the invention asdefined in the claims, and this application is limited only by the scopeof the claims.

1. A method of operating a multiple row meat patty forming apparatuscomprising: sliding a mold plate defining first row of a first pluralityof cavities and a second row of a second plurality of cavities so thatthe first plurality of cavities in the first row and at least one of thesecond plurality of cavities in the second row simultaneouslycommunicate fluidly with a slot defined by a fill plate, the fill plateenabling pressurized meat to pass through the fill plate and into thefirst plurality of cavities and the second plurality of cavities of thefirst and second rows respectively, wherein the first row and the secondrow are staggered such that along the slot defined by the fill plate,the first plurality of cavities overlap with the second plurality ofcavities.
 2. The method of claim 1, which includes sliding the moldplate across the fill plate in multiple directions.
 3. The method ofclaim 2, which includes holding the first row of cavities in fluidcommunication with the slot for an amount of time prior to sliding themold plate in a different direction.
 4. The method of claim 1, whichincludes stacking the first row and the second row with respect to eachother.
 5. The method of claim 1, wherein the slot defined by the fillplate includes a plurality of individual slots.
 6. The method of claim1, further comprising stopping the mold plate for filling when the slotis midway through a back third of the first or second row.